Chapter 10 - Wire arc additive manufacturing: A comprehensive review on methodologies and processes to overcome challenges with metallic alloys

Abstract

Wire arc additive manufacturing also referred to as wire arc additive manufacturing (WAAM) is one of the promising technologies in AM industry that has the capability for mass production. As one of the leading innovative techniques in directed energy deposition (DED) category, WAAM has been used in the application of higher deposition of materials. Compared to other techniques in DED, the deposition, low-material wastage, economic and structural aspects associated with WAAM makes it a good substitution to traditional manufacturing practices such as forging, casting, etc., particularly for making complex design products (nowadays topology optimized products are as well preferred over existing design). The major metal alloys used for this technique involve nickel, titanium, stainless steel and aluminum. This paper discusses on progress made into managing residual stresses incurred, improving mechanical properties. Furthermore, this paper also discusses the aspects of eliminating defects that occurred during manufacturing such as porosity and low resolution. Finally, industrial applications, success associated with the application of this technology, and scope of improvements are reviewed and discussed in detail.